US5093208A - Laminated metal sheet - Google Patents

Laminated metal sheet Download PDF

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Publication number
US5093208A
US5093208A US07/642,566 US64256691A US5093208A US 5093208 A US5093208 A US 5093208A US 64256691 A US64256691 A US 64256691A US 5093208 A US5093208 A US 5093208A
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Prior art keywords
polyester
process according
laminate
film
metal
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Expired - Fee Related
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US07/642,566
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English (en)
Inventor
Peter J. Heyes
Nicholas J. Middleton
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Crown Packaging UK Ltd
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CMB Foodcan PLC
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B32B15/09—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B1/00—Layered products having a non-planar shape
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/18—Layered products comprising a layer of metal comprising iron or steel
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/06—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/08—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the cooling method
    • B32B37/085—Quenching
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
    • B32B37/20—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of continuous webs only
    • B32B37/203—One or more of the layers being plastic
    • B32B37/206—Laminating a continuous layer between two continuous plastic layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/0036—Heat treatment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/02—Physical, chemical or physicochemical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D1/00—Containers having bodies formed in one piece, e.g. by casting metallic material, by moulding plastics, by blowing vitreous material, by throwing ceramic material, by moulding pulped fibrous material, by deep-drawing operations performed on sheet material
    • B65D1/22—Boxes or like containers with side walls of substantial depth for enclosing contents
    • B65D1/26—Thin-walled containers, e.g. formed by deep-drawing operations
    • B65D1/28—Thin-walled containers, e.g. formed by deep-drawing operations formed of laminated material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/06—Coating on the layer surface on metal layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/20—Inorganic coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/514—Oriented
    • B32B2307/518—Oriented bi-axially
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/02—Temperature
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2310/00—Treatment by energy or chemical effects
    • B32B2310/04—Treatment by energy or chemical effects using liquids, gas or steam
    • B32B2310/0409—Treatment by energy or chemical effects using liquids, gas or steam using liquids
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2311/00—Metals, their alloys or their compounds
    • B32B2311/24—Aluminium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2311/00—Metals, their alloys or their compounds
    • B32B2311/30—Iron, e.g. steel
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2367/00—Polyesters, e.g. PET, i.e. polyethylene terephthalate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2439/00—Containers; Receptacles
    • B32B2439/40—Closed containers
    • B32B2439/66—Cans, tins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2439/00—Containers; Receptacles
    • B32B2439/70—Food packaging
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12535—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.] with additional, spatially distinct nonmetal component
    • Y10T428/12542—More than one such component
    • Y10T428/12549—Adjacent to each other
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12535—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.] with additional, spatially distinct nonmetal component
    • Y10T428/12556—Organic component
    • Y10T428/12569—Synthetic resin
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
    • Y10T428/1334—Nonself-supporting tubular film or bag [e.g., pouch, envelope, packet, etc.]
    • Y10T428/1338—Elemental metal containing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
    • Y10T428/1352—Polymer or resin containing [i.e., natural or synthetic]
    • Y10T428/1355—Elemental metal containing [e.g., substrate, foil, film, coating, etc.]
    • Y10T428/1359—Three or more layers [continuous layer]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31678—Of metal
    • Y10T428/31681—Next to polyester, polyamide or polyimide [e.g., alkyd, glue, or nylon, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31786—Of polyester [e.g., alkyd, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31786—Of polyester [e.g., alkyd, etc.]
    • Y10T428/31797—Next to addition polymer from unsaturated monomers

Definitions

  • the present invention relates to laminated metal sheet and to a process for producing such laminated metal sheet.
  • Lamination of polymer materials to metal sheet such as metal strip is a well known and well documented technique.
  • the resultant laminates have many applications including use for the manufacture of drawn and wall-ironed cans, (also referred to as DWI cans).
  • the present invention provides a laminated metal sheet, one or both surfaces of the metal sheet having adhered directly thereto a film of a non-crystalline polyester.
  • the non-crystalline polyester (also referred to herein as an amorphous polyester) should be substantially free from orientation as determined by x-ray diffraction or density measurements.
  • Crystallinity can be measured from density measurements as follows.
  • V c Volume fraction crystallinity
  • V c (P-P a ). (P-P c ) -1
  • P c density of crystalline polyester.
  • the density measurements can be made in zinc chloride/water solution or n-heptane/carbon tetrachloride using a density column.
  • the non-crystalline polyester is a polyethylene terephthalate (PET) or a polybutylene terephthalate (PBT).
  • PET polyethylene terephthalate
  • PBT polybutylene terephthalate
  • the PET materials preferably have an intrinsic viscosity between 0.5 and 1.1 as measured in o-chlorophenol at 25° C. and a concentration of 5 gm per liter.
  • the non-crystalline polyester film laminated to the metal sheet is obtained by laminating to the metal sheet a film comprising a polyester, with the conditions under which the lamination is performed being such that during lamination the polyester film or films in the metal/polymer laminate is or are converted into non-crystalline (or amorphous) form.
  • each of the major surfaces of the metal sheet carries a film of non-crystalline polyester as defined above.
  • the scope of the invention encompasses metal sheet carrying a non-crystalline polyester on one major surface with a layer of a different thermoplastic polymer film on the other major surface of the metal sheet.
  • the metal substrate to which the polymer films are applied is generally steel or aluminium or alloys thereof, typically a steel or aluminium based product used in the packaging industry.
  • the gauge range is typically 0.05 mm to 0.4 mm for steel and 0.02 mm to 0.4 mm for aluminium; generally 0.25 mm to 0.35 mm for steel and aluminium DWI cans.
  • the steel may be coated with tin, preferably passivated by conventional chromic treatments, or alternatively may be in the form of nickel or zinc plated steel, blackplate or phosphated blackplate, which is preferably chromate rinsed after phosphating.
  • the preferred steel finish is electrolytically chromium coated steel (ECCS) with a dual layer of chromium metal and chromium oxide.
  • ECCS electrolytically chromium coated steel
  • the chromium metal and chromium oxide levels can vary widely.
  • the chromium metal content ranges from 0.01 to 0.20 gm/m 2
  • the chromium oxide ranges from 0.005 to 0.05 gm/m 2 .
  • the ECCS is commonly derived from deposition systems containing either sulphur containing or fluorine containing catalysts.
  • the aluminium which is used is preferably a 3004 type alloy with either an as-rolled ("mill") finish, a cleaned and optionally oiled finish, or a cleaned and chromate or chromate-phosphate treated, optionally oiled, finish.
  • Alocrom A272 is a proprietary chromate-phosphate treatment system for aluminium strip.
  • polyester film A number of different types can be used to prepare the metal polymer laminate.
  • Typical polyester materials suitable for use in preparing the metal polymer laminate of the invention are:
  • thermoplastic polyester such as polyethylene terephthalate or polybutylene terephthalate.
  • (A1) an inner layer of a substantially non-crystalline linear polyester having a softening point below 200° C. and a melting point below 250° C. but above 150° C., and
  • (A2) an outer layer of a biaxially oriented linear polyester having a crystallinity greater than 30%.
  • the outer layer (A2) is a PET homopolymer. Its intrinsic viscosity is preferably between 0.5 and 1.1, more preferably 0.6 to 0.7, for biaxially oriented film and greater than 0.9 for cast film.
  • the thinner inner layer (A1) is typically a substantially non-crystalline linear copolyester of 80% ethylene terephthalate and 20% ethylene isophthalate.
  • the inner layer is a substantially non-crystalline copolyester derived from terephthalic acid and two dihydric alcohols such as ethylene glycol and cyclohexane-dimethanol.
  • polyester layers can be pigmented, for example with anti-blocking agents such as synthetic silica or pigments giving a coloured or white appearance, for example titanium dioxide. It is particularly preferred to pigment layer A2 with titanium dioxide for the outside surface of a beverage can formed from the laminate.
  • the coextruded film's outer layer (A2) is polyethylene terephthalate.
  • the inner amorphous layer (A1) is a linear copolyester, for example an amorphous copolymer of approximately 80% ethylene terephthlate and approximately 20% ethyleneisophthalate. Copolyesters of terephthalic acid and two alcohols, for example ethylene glycol and cyclohexane-dimethanol, are also suitable for use as the inner amorphous layer (A1).
  • the crystallinity of the outer crystalline layer (A2) is typically 50%, but can be reduced to 40% or less if the biaxial orientation of the crystalline polymer is reduced.
  • Biaxially oriented film may be formed by stretching the amorphous extruded polymer in the forward direction at temperatures above the glass transition temperature of the polymer by a factor of 2.2 to 3.8 and similarly in the transverse direction by 2.2 to 4.2.
  • the laminated metal sheet of the invention is prepared by a process which comprises adhering directly to one or both major surfaces of the metal sheet a film comprising a polyester, the lamination conditions being such that during lamination the polyester film or films in the metal/polymer laminate is or are converted into non-crystalline or amorphous form.
  • polyester monolayer film or films are adhered to the metal sheet by heating the metal sheet to a temperature (T1) above the melting point of the polyester films, the temperature (T1) being such that during lamination of the polyester films to the metal sheet, the outer surfaces of the polyester films remain below their melting points, laminating the film or films to the metal sheet, reheating by indirect means the laminate to a temperature (T2) above the melting points of the polyester films and after holding at these elevated temperatures, quenching rapidly the polyester coated metal to a temperature below the glass transition points of the polyester coating resins.
  • T1 temperature above the melting point of the polyester films
  • the polyester film or films are composite films (A) comprising an inner layer (A1) and an outer layer (A2), and the composite polyester films are simultaneously adhered to the metal sheet by a process which comprises
  • the said composite polyester films are preferably co-extruded polyester films comprising
  • (A1) an inner layer of substantially non-crystalline linear polyester having a softening point below 200° C. and a melting point below 250° C. but above 150° C.
  • polyesters having intrinsic viscosities of 0.5 to 1.1 measured in o-chlorophenol at 25° C. and a concentration of 5 gm per liter.
  • the metal/polymer laminate is preferably re-heated downstream of the lamination nip by use of induction heating means, but infrared heating may also be used.
  • induction heating means but infrared heating may also be used.
  • the temperature to which the metal sheet should be heated prior to lamination depends both on the thickness of the films to be laminated and also on the chemical nature of the said films.
  • the uncoated metal may be treated by direct or indirect means for example, induction, infrared, hot air or hot rollers.
  • Temperatures of 140° C. to 350° C. are suitable for coextruded biaxially oriented PET film, 130° C. to 250° C. for cast coextruded polyester film, 260° C. to 350° C. for biaxially oriented PET monofilm of high crystallinity or 200° C. to 300° C. for PET film of low crystallinity and above 180° C. for cast PBT monofilm.
  • the temperatures to be used on reheating the laminate downstream of the lamination nip typically are above 270° C. for polyethylene terephthalate and 240° C. for polybutylene terephthalate.
  • Commercial operations generally demand a dwell time of approximately two seconds only between the reheating operation and quenching.
  • the quenching is uniform and rapid and can be accomplished by curtains of cold water directed at the strip.
  • the laminate should be quenched from temperatures above about 190° C.; to prevent blistering the coating should be quenched from below the melting point.
  • the laminates of this invention are particularly suited for forming into drawn and wall ironed cans (DWI).
  • DWI drawn and wall ironed cans
  • an aluminium beverage can undergoes the following operations:
  • the conventional printing operation can be replaced by a dye sublimation printing process as such as described in GB 2101530, 2145971, 2141382, 2010529, 2141972 and 2147264.
  • a paper label impregnated with a sublimable dye is wrapped around the can and held firmly to itself with a small amount of adhesive at the paper overlap.
  • the can is passed through an oven at a temperature above the sublimation point of the dye and the print is transferred without the use of solvent.
  • the label can be stripped with air jets, leaving a printed can with excellent print quality. This is a solvent-free process, substantially free from atmospheric emissions.
  • Drawn and wall-ironed cans made from the laminate materials of the invention can be decorated and printed with conventional solvent based inks after the DWI can is formed.
  • thermoplastic polyester coatings on metal sheet will accept sublimed dyes.
  • a high quality decoration from a paper label is only achieved if there is retained orientation in the PET coating. If the coating is amorphous, either because it has been melted in the lamination process or was derived from an unoriented film, the paper label sticks to the coating during the sublimation stage and marrs the decoration.
  • the sublimation from paper label is carried out by establishing intimate contact between paper and coating and heating to temperatures above 160° C. and usually up to 220° C. Under these conditions non-oriented PET is above its glass transition (Tg), relatively soft and will tack to paper. If the outer part, at least, of the coating retains biaxial orientation, the paper does not stick to the polyester during dye sublimation.
  • Tg glass transition
  • the outer, oriented material in contact with the paper has a modified thermal behaviour and its effective glass transition is not encountered during dye sublimation.
  • DWI cans formed from amorphous polyester coated laminates in accordance with the present invention can be successfully decorated by dye sublimation using standard labels and sublimation conditions.
  • the label application must preferably be modified slightly to avoid label contact with approximately the bottom 2 mm of the can wall, as denoted "d" in FIG. 7a of the accompanying drawings. If this procedure is followed the paper will not stick to or marr the coating. Generally speaking, an amorphous coating of polyester will stick to paper if it is in contact above its Tg. However, the can forming operation introduces orientation into the polyester coatings of the laminates of the present invention and thereby raises the effective Tg. The amount of induced orientation is relatively small even at the can wall top and very different for internal and external coatings, so it is surprising that the beneficial effect which prevents paper sticking is so pronounced.
  • the laminates described in this invention can surprisingly be manufactured into DWI cans whilst retaining excellent coating integrity and adhesion. Furthermore the coated containers can be decorated by conventional printing or by a dye sublimation process.
  • the laminates of the present invention can also be used to manufacture other packaging components, particularly non-retorted packaging components. Typical examples of such other components are:
  • Draw redraw cans for beverage products for example 54 mm diameter by 70 mm height cans made from 0.21 mm ECCS, 350 N/mm 2 .
  • Scored easy open beverage can ends for example 65 mm steel or aluminium ends.
  • Integral neck oblong ends for oblong containers Integral neck oblong ends for oblong containers.
  • Paint can end components such as ring, ends and caps.
  • Aerosol end components such as cones and domes.
  • FIGS. 1 and 2 show diagrams of apparatus suitable for performing the process of the present invention
  • FIG. 3 shows a section taken through a laminate in accordance with the invention and comprising mono-layered polymer films (A) laminated to a metal strip (M);
  • FIG. 4 shows a section taken through a laminate similar to that of FIG. 3 but having a composite multi-layered polymer film (A) laminated to a metal strip (M);
  • FIG. 5 shows a section taken through a laminate similar to that of FIG. 4 but containing an additional film (B) of thermoplastic polymer laminated to the opposite side of the metal strip (M);
  • FIG. 6 shows a can end formed from a laminate in accordance with the invention.
  • FIGS. 7a and 7b respectively show a drawn and wall-ironed can and a draw-redraw can formed from a laminate in accordance with the invention.
  • Polymer/metal/polymer laminates were prepared by a lamination process performed in apparatus as illustrated schematically in FIG. 1 or FIG. 2 of the accompanying drawings.
  • a metal sheet M was pre-heated by infrared or induction heating to an appropriate temperature T 1 by a heater 1. Temperature T 1 is usually within the range 140° and 350° C.
  • Polyester films A and B were fed from feed rolls 2 and 4 and laminated to the opposite sides of the pre-heated metal sheet between lamination rolls 6, 8, typically having a diameter of 100-400 mm.
  • Lamination was generally performed using a nip force of 200-400N per meter between the lamination rolls.
  • the resultant laminate is re-heated, preferably by use of an induction heater 10 or by infrared heating, to a laminate temperature T 2 at which the polymer films (A) will interact with and become strongly bound to the metal sheet.
  • Temperature T 2 is usually within the range 220 ° and 270° C. for PBT and 260° to 300° C. for PET.
  • the metal polymer laminate is held at temperature T 2 or a temperature below T 2 for a short period of time, usually no more than 2 seconds, and is then rapidly and uniformly quenched with water to a temperature below the glass transition point of the polyester in the films, for example about 80° C. for PET.
  • Quenching can be performed in any conventional manner, but typically can be performed by passing the laminate through a tank 12 of water as shown in FIG. 1 or by passing the laminate through curtain 14 of quenching water as shown in FIG. 1 and FIG. 2.
  • FIG. 1 also shows a schematic diagram of a typical temperature profile which would be found in the process illustrated in the apparatus of FIG. 1.
  • laminates were prepared from the materials given in Table I by preheating the metal strip by infrared or induction heating, passing the metal strip and polymer films into a pair of nip rolls and laminating both major metal surfaces simultaneously with the polymer films.
  • the resultant laminate was reheated by infrared or induction, held above 200° C. for two seconds and quenched rapidly and uniformly with cold water.
  • Table II sets out a number of Examples showing the results obtained when preparing such laminates using various metal temperatures (T 1 ) in the pre-lamination stage and various reheating temperatures (T 2 ) in the post-lamination stage.
  • the laminate formability was assessed by coating coverage after draw and wall ironing the laminate in two stages:
  • Stage 1 a cup (height 35 mm, diameter 86 mm) was drawn from the laminate, suitably lubricated.
  • Stage 2 a can body (diameter 65 mm, height 130 mm) was formed by redrawing and wall ironing.
  • the cans were rinsed in water and dried. Coating coverage was assessed by immersion in acidified copper sulphate for two minutes and visually inspecting for copper deposits or the "enamel rating" technique using a sodium chloride solution, a voltage of 6.3V and measuring current in milliamps.
  • the influence of lamination temperatures on the polyester coating structure and formability of the laminate was assessed by x-ray diffraction.
  • the film or laminate is placed in an X-ray diffractometer.
  • Count rates are measured when the flat samples are exposed to a beam of substantially monochromatic x-rays using an appropriate detector.
  • the sample and detector are rotated in line with respect to the beam, maintaining the geometry such that the angle between the sample and beam ( ⁇ ) and beam and detector remain in the ratio 1:2, as in a normal powder diffraction scan. This data generates information on planes parallel to the sample surface.
  • Laminate material B laminated in accordance with the teaching of GB 2123746 to retain orientation had poor formability and failed to make cans without metal breaking or severe coating disruption. However, when laminate material B was processed to eliminate orientation and crystallinity, as in Example 3, it had excellent formability and afforded good protection after forming.
  • biaxially oriented coextruded laminate materials C and J also gave good formability if amorphous, and poor formability if they retained orientation in the laminate (compare Example 5 with Example 6 and Example 13 with Example 14).
  • Cast, unoriented PET or PBT coatings were effective, provided they were laminated to produce an amorphous and not a crystalline condition.
  • a crystalline condition is produced for example by slow cooling from the reheated stage.
  • Examples 11 and 12 show that laminates formed from polypropylene materials of the type described in GB 2003415 exhibited poor formability. Such laminates were found to give metal failure in can forming.
  • the XRD data confirms that the laminated sheet had amorphous coatings and shows that the upper can wall is slightly oriented, more so for the can outside coating.
  • the lower 2 mm of the can wall external coating were not significantly affected by can forming and remained essentially amorphous.
  • the external walls of DWI cans formed from the laminates of Examples 1 to 13 were decorated by a conventional dye sublimation process.
  • the quality of the resultant decoration was found to be excellent, provided the label was not in contact with the lower 2 mm of the can wall, region "d" of FIG. 7a.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Laminated Bodies (AREA)
  • Ceramic Capacitors (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
  • Physical Or Chemical Processes And Apparatus (AREA)
US07/642,566 1987-10-15 1991-01-18 Laminated metal sheet Expired - Fee Related US5093208A (en)

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ATE87262T1 (de) 1993-04-15
FI892902A (fi) 1989-06-14
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KR890701355A (ko) 1989-12-20
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HK30495A (en) 1995-03-17
BG51346A3 (en) 1993-04-15
RU2080265C1 (ru) 1997-05-27
EP0312304B1 (en) 1993-03-24
WO1989003303A1 (en) 1989-04-20
RU2037426C1 (ru) 1995-06-19
PT88730B (pt) 1993-12-31
TR26709A (tr) 1994-07-06
ES2040352T3 (es) 1993-10-16
GB2211465A (en) 1989-07-05
GB8724239D0 (en) 1987-11-18
CN1032765A (zh) 1989-05-10
EP0312304A1 (en) 1989-04-19
FI892902A0 (fi) 1989-06-14
CA1313494C (en) 1993-02-09
DD299521A5 (de) 1992-04-23
DK292989A (da) 1989-08-11
MY104840A (en) 1994-06-30
KR890701356A (ko) 1989-12-20
GB8823927D0 (en) 1988-11-16
CN1045923C (zh) 1999-10-27
JPH02501638A (ja) 1990-06-07
KR960000730B1 (ko) 1996-01-12
CN1065825A (zh) 1992-11-04
ZA887620B (en) 1989-06-28
PL275218A1 (en) 1989-06-12
GB2211465B (en) 1992-04-29
SG12995G (en) 1995-06-16
NO892422D0 (no) 1989-06-13
YU219389A (en) 1991-06-30
FI100705B (fi) 1998-02-13
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AU2547788A (en) 1989-05-02
DE3879610D1 (de) 1993-04-29
HUT56766A (en) 1991-10-28
KR960000731B1 (ko) 1996-01-12
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PT88730A (pt) 1989-07-31
BR8807250A (pt) 1990-03-01

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